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- Title
Optimization of side outlet holes in rotary sinking electrochemical milling of Ti6Al4V through the simulation of electric and flow fields.
- Authors
Yue, Xiaokang; Qu, Ningsong
- Abstract
Rotary sinking electrochemical (RSEC) milling is a version of electrochemical milling that can be adopted to machine some aerospace parts. When the cutting depth is kept constant during the RESC milling, the material removal rate (MRR) is directly proportional to the feeding speed, and the feeding speed is dependent on the current density of the workpiece surface, which is affected by the layout of the side outlet hole. To increase MRR, a new principle based on simulations of electric and flow fields is proposed to optimize the number and diameter of side outlet holes. Through the electric field simulation, the positions of key points with the lowest average current density at side and corner regions are confirmed. On this basis, the average dissolution rate in a rotation cycle is calculated to determine the optimal number of outlet holes. Subsequently, via the dynamic flow field simulation, the average value and standard deviation of electrolyte speed in the machining gap are obtained to further optimize the tool geometry with various diameters and numbers of outlet holes. Finally, the maximum feeding speed and MRR are measured experimentally at different applied voltages, and the results verify the effectiveness of the new optimal principle.
- Publication
International Journal of Advanced Manufacturing Technology, 2024, Vol 132, Issue 7/8, p3593
- ISSN
0268-3768
- Publication type
Article
- DOI
10.1007/s00170-024-13606-8